High-power electrical quick connector

ABSTRACT

A quick connector assembly for high power electrical applications and method of manufacturing a high-power quick connector assembly are disclosed. The quick connector assembly has a first connector and a second connector constructed to form an electrical connection that can be quickly coupled and decoupled. The first connector has a collar portion connectable to a welding cable and a stem portion having a shank section and a threaded section. The second connector has a recess constructed to receive the stem portion of the first connector and electrically engage both the shank portion and the threaded portion of the first connector.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a divisional and claims priority of U.S.patent application Ser. No. 10/711,475 filed Sep. 21, 2004, thedisclosure of which is incorporated herein.

BACKGROUND OF THE INVENTION

The present invention relates generally to welding-type devices, andmore particularly, to a quick connector assembly for use therewith.

Welding-type devices generally have a power source configured togenerate a power signal suitable for welding-type applications. Thispower signal is transmitted beyond the power source by connecting a pairof cables to the power source. One of the cables has a torch at an endthereof and another cable has a work clamp attached at an end thereof.The cables are of such length as to allow an operator to position thetorch and work clamp proximate the work piece. Additionally, the cablesprovide an operator with flexibility in the positioning the work piecerelative to the power source.

During a welding process, weld power is transmitted through the weldcables to the torch and work clamp. As an operator performs a weldingprocess, the weld cable must often be repositioned during the weldingprocess. An operator may inadvertently apply stresses to the connectionbetween the weld cable and the power source during repositioning of theweld cables. Inadvertent overstressing of the connection can result inpoor electrical connectivity between the weld cable and the powersource. Poor electrical connectivity between the weld cable and thepower source can detract from weld quality and result in wear betweenthe components of the connection. Ultimately, the connection can beoverstressed to a point of mechanical failure or disengagement. As such,the connection between the weld cable and the power source must bedesigned to withstand such inadvertent stresses.

While some connectors provide a relatively robust mechanical connection,such as by bolting the weld cable to the power source, suchconstructions are not without their drawbacks. Specifically,welding-type devices that require the weld cable be bolted to the powersource detract from the ease of portability of such devices and theinterchangeability of weld cables. The weld cables are often removedduring transportation of the welding device in order to protect theelectrical integrity of the weld cables. In order to move thewelding-type device, the operator must not only remove the cables butmust also acquire the tool/tools required to disengage the bolt from thepower source. Similarly, if a particular welding application requires alonger set of cables, an operator must remove a first set of cables andconnect a second set of longer cables. As such, in highly dynamicapplications where the power source may be relocated several times a dayor welding processes may be required at different distances from thewelding device, repeatedly disconnecting and reconnecting the weldcables decreases the overall efficiency of welding operations.

In addition to the mechanical considerations, the connection between thepower source and the weld cable must also be able to thermally andelectrically support the transfer of the power signal suitable forwelding through the connection. As the amount of current passed throughthe connection increases, the temperature of the components of theconnection also increases and is indicative of power loss associatedwith the connection. Heat generated in the connection decreases theelectrical efficiency of the connection. Additionally, if leftunaddressed, the temperature of the connector can ultimately lead tofailure of the connection or damage to other components of thewelding-type device including the welding cables, the torch, the weldingdevice housing, or the internal components of the welding-type device.As such, the connection between the weld cable and the power source maynot only decrease the overall efficiency of the welding-type device butmay also define a limit for the amount of welding power that can becommunicated through the connection.

It would therefore be desirable to have a connector assembly that isquickly connectable to a welding-type device and can withstand thetransfer of relatively high weld power signals therethrough.

BRIEF DESCRIPTION OF THE INVENTION

The present invention is directed to a connector assembly that solvesthe aforementioned problems. The present invention provides a connectorassembly and method of manufacturing the same that allows a firstconnector to be quickly connected to and disconnected from a secondconnector. The connector is constructed to mechanically and electricallyconnect a weld cable to a welding-type device capable of generatingrelatively high power signals suitable for multiple weldingapplications.

Therefore, in accordance with one aspect of the present invention, ahigh-power quick connector assembly is disclosed having a firstconnector and a second connector. The first connector has a collarportion connectable to a welding cable and a stem portion having a shankend and a threaded end. The second connector has a recess formed thereinconstructed to receive the stem portion of the first connector. Therecess is constructed to engage the shank end and the threaded end ofthe first connector.

According to another aspect of the present invention, a quick connectorassembly for a welding-type device is disclosed. The quick connectorassembly includes a cable adapter having a cable end connectable to awelding cable and a welding device end. A device adapter is constructedto engage the welding device end of the cable adapter and has a bodyhaving a first end and a second end. A recess extends into the body fromthe first end and has a threaded section formed in the recess proximatethe first end. A smooth section is formed in the recess between thethreaded section and the second end.

In accordance with another aspect of the present invention, a high-powerquick connector assembly is disclosed having a receiver and a plug. Thereceiver is configured to be connected to a welding-type device and hasa first inner diameter and a second inner diameter wherein the secondinner diameter is greater than the first inner diameter. The plug isconstructed to be connected to a weld cable and has a stud. The stud hasa first outer diameter substantially similar to the first inner diameterof the receiver and a second outer diameter substantially similar to thesecond inner diameter of receiver. A plurality of threads is formedabout the second outer diameter of the stud.

According to a further aspect of the present invention, a method offorming a high-power electrical connection is disclosed. The methodincludes providing a receptacle having a first connection portion and asecond connection portion, providing a plug having a first engagementportion constructed to electrically communicate with the firstconnection portion of the receptacle and a second engagement portionconstructed to electrically communicate with the second connectionportion upon rotation therebetween, and wherein a surface area of thefirst engagement portion is less than a surface area of the secondengagement portion.

According to yet another aspect of the present invention, a method ofmanufacturing a high-power quick connector assembly is disclosed. Themethod includes forming a receiver having a first internal profile and asecond internal profile and forming a plug having a first externalprofile constructed to pass the second internal profile of the receiverand engage the first internal profile of the receiver and a secondexternal profile constructed to engage the second internal profile ofthe receiver upon rotation therebetween.

In accordance with a further aspect of the present invention, ahigh-power quick connector assembly for welding-type apparatus isdisclosed. The high-power quick connector assembly includes means forreceiving a weld cable and means for connecting the receiving means to apower source. The connecting means includes first attaching means havinga contact surface area and second attaching means having a contactsurface area that is greater than the contact surface area of the firstattaching means.

According to an even further aspect of the present invention, aconnector assembly is disclosed having a cable connector and an outputconnector. The cable connector is connectable to a weld cable and theoutput connector is electrically connectable to a power sourceconfigured to generate a power signal suitable for welding applications.At least one of the cable connector and the output connector areconstructed from a tellurium copper material.

Various other features and advantages of the present invention will bemade apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplatedfor carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of an exemplary welding-type deviceincorporating the present invention.

FIG. 2 is an elevation view of one embodiment of a quick connectorassembly for use with the welding-type device shown in FIG. 1.

FIG. 3 is a perspective, partial cross-sectional view, of the quickconnector assembly of FIG. 2.

FIG. 4 is an exploded perspective view of the quick connector assemblyof FIG. 2.

FIG. 5 is an end view of a first connector of the connector assemblytaken along line 5-5 of FIG. 2.

FIG. 6 is an end view of a second connector of the connector assemblytaken along line 6-6 of FIG. 2.

FIG. 7 is an elevational view of the connector assembly of FIG. 2 withthe first connector inserted into the second connector which is shown incross-section.

FIG. 8 is an elevational view of the connector assembly of FIG. 7 withthe first connector rotated into engagement with the second connector.

FIG. 9 is an end view of the connector assembly taken along line 9-9 ofFIG. 7 with the first connector inserted into the second connector.

FIG. 10 is an end view of the connector assembly taken along line 10-10of FIG. 7 with the pin of the second connector positioned in the grooveof the first connector.

FIG. 11 is an end view of the connector assembly taken along line 11-11of FIG. 8 with the threaded portion of the first and second connectorsrotated into engagement.

FIG. 12 is an end view of the connector assembly taken along line 12-12of FIG. 8 with the pin and groove of the first and second connectorsrotated to the engaged position.

FIG. 13 is a perspective, partial cross-sectional view, of anotherembodiment of a quick connector assembly for use with the welding-typedevice shown in FIG. 1.

FIG. 14 is an end view of a first connector of the connector assemblytaken along line 14-14 of FIG. 13.

FIG. 15 is an end view of a second connector of the connector assemblytaken along line 15-15 of FIG. 13.

FIG. 16 is an elevational view of the connector assembly of FIG. 13 withthe first connector inserted into the second connector which is shown incross-section.

FIG. 17 is an elevational view of the connector assembly of FIG. 13 withthe first connector and the second connector rotated into engagement.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention will be described with reference to a welder;however, it is understood that its application is not so limited.Referring now to FIG. 1, a portable engine-driven welder system 10 isprovided and, for brevity, will hereinafter be referred to as thewelding device 10. As one skilled in the art will fully appreciate, theheretofore description of welding devices not only includes welders, butalso includes any system that requires high power outputs, such asheating and cutting systems. Therefore, the present invention isequivalently applicable with any device requiring high power output,including welders, plasma cutters, induction heaters, aircraft groundpower units, and the like. Reference to welding power, welding-typepower, or welders generally, includes welding, cutting, heating power,or ground power for aircraft. Description of a welding apparatusillustrates just one embodiment in which the present invention may beimplemented. The present invention is equivalently applicable with manyhigh power systems, such as cutting and induction heating systems,aircraft ground power systems or any similar systems.

The welding device 10 has an outer housing 12 that has one or more airvents 14 for cooling internal components of welding device 10. Thehousing 12 can be easily removed to permit access to the internalcomponents for maintenance and service. An upper surface 20 of weldingdevice 10 includes a lifting hook 22 extending therethrough for liftingand transporting of the welding device. Also attached to the uppersurface 20 is an exhaust system 24 that lowers noise and passes exhaustgas from an engine of welding device 10 through housing 12. Weldingdevice 10 is shown as being engine driven for exemplary purposes. It isunderstood that welding device 10 could be powered by an external powersource such as a power grid.

The welding device 10 includes a control panel 26 that has variouscontrol elements and gauges for operating the welding device 10. Aplurality of gauges 28 measure various parameters of the welding device10. Measured parameters can include oil pressure, fuel level, oiltemperature, battery amperage, air pressure, and engine running time ofthe welding device 10. Control panel 26 also has a control dial 30 andan ampere range switch 32 which are used to select a voltage/amperagefor welding operations. Process selector switch 34 selects the type ofweld output. The weld output is determined by the type of weldingprocess. Examples of weld processes that may be implemented includestick welding, gas metal arc welding, tungsten inert gas welding,air-carbon arc cutting, and various wire feed processes. Electricaloutlets 36 provide power for electrically driven devices, such as saws,drills, etc. Control panel 26 also includes a compressor on/off switch31 and an engine control switch 33 to independently control thecompressor and engine, respectively.

The control panel 26 also includes multiple power connections such as asingle phase power connect 38, an optional three-phase power connect 40,and weld-power receptacles 42. Weld cable connectors 44 are connected towelding cables 46 and are constructed to engage weld-power receptacles42. Weld cables 46 electrically connect a torch and a work clamp towelding device 10. Weld-power receptacles 42 and weld cable connectors44 form a connector assembly 48 for removably connecting weld cables 46to welding device 10. An optional polarity switch 50 can be used toselect the polarity of the weld output. Typical selections includedirect current electrode negative, direct current electrode positive,and alternating current. A panel remote switch 52 and remote receptacle53 select remote control of the welding device 10 in instances wherewelding operations are remotely located from the welding device 10.

One embodiment of connector assembly 48 is shown in greater detail inFIG. 2. Weld cable connector 44, a first connector, has a collar portion54 and a stem portion 56. Collar portion 54 is constructed to receiveweld cable 46 therein and has an insulator 55 positioned thereabout. Aset screw 57 is threadingly received in a threaded hole 59 formedthrough collar portion 54 and receives weld cable 46 therein. Insulator55 positioned about connector 44 protects connector 44 from inadvertentelectrical contact therewith when connector 44 is connected toreceptacle 42. Stem portion 56 includes a shank portion 58 and athreaded portion 60. Shank portion 58 is located at an end 62 of weldcable connector 44 generally opposite another end 64 of weld cableconnector. A groove 66 is formed in shank portion 58 and has a firstsection 68 extending generally longitudinally along shank portion 58 ofweld cable connector 44. A second section 70 of groove 66 extendsgenerally circumferentially about stem portion 56 at an interface 72 ofshank portion 58 and threaded portion 60. Threaded portion 60 includes aplurality of threads 74 extending circumferentially thereabout. A pairof planar surfaces 76 extend longitudinally along shank portion 58 andthreaded portion 60 from end 62 to a lip 78 between threaded portion 60and collar portion 54 of weld cable connector 44. Planar surfaces 76interrupt threaded portion 60 such that threads 74 do not extendcontinuously thereabout. Planar surfaces 76 also truncate shank portion58 of stem portion 56. Receptacle 42 forms a second connector ofconnector assembly 48.

Receptacle 42 includes a first collar 80 and a second collar 82 withhousing 12 of welding device 10 positioned therebetween. A boss 84extends from an outer surface 86 of second collar 82 and positions firstcollar 80 relative thereto. A nut 88 engages an outer threaded portion90 of receptacle 42 and secures the receptacle to housing 12. A washer92 is positioned between nut 88 and second collar 82 and preventsunintentional loosening of receptacle 42 from housing 12. A bolt 94secures a clip 96 to receptacle 42. Clip 96 electrically connectsreceptacle 42 to a power source constructed to generate a welding-typepower signal. A recess 98 is formed in receptacle 42 as shown in FIG. 3.Recess 98 includes a first section 100, a second section 102, and athird section 104. Third section 104 of recess 98 includes a pluralityof threads 106 formed thereabout for receiving bolt 94 shown in FIG. 2.It is understood that, rather than receiving a solid bolt, third section104 could receive a hollow adapter to allow circulation of a coolingflow through connector assembly 48.

As shown in FIG. 3, first section 100 of recess 98 has a threadedportion 108 interrupted by a pair of channels 109. Channels 109 extendacross threaded portion 108 and divide it into a pair of threadedsections. A pin 110 extends into recess 98 generally between firstsection 100 and second section 102. As weld cable connector 44 isinserted into receptacle 42 in the direction of arrow 112, pin 110engages groove 66 and moves along first section 68 of groove 66. Uponrotation of weld cable connector 44 relative to receptacle 42, pin 110translates along second section 70 of groove 66 and threaded portion 60of weld cable connector 44 engages threaded portion 108 of receptacle42.

An exploded view of connector assembly 48 is shown in FIG. 4. Stemportion 56 of weld cable connector 44 engages recess 98 of a conductivebody 112 of receptacle 42. Pin 110 passes through conductive body 112and engages groove 66 of weld cable connector 44. An exterior surface114 of conductive body 112 includes a hex portion 116, a mid-planarportion 118, and threaded portion 90. An O-ring 122 passes over threadedportion 90 and partially across mid-planar portion 118. O-ring 122 isreceived in an annular groove 124 formed about mid-planar portion 118.First collar 80 has an opening 126 formed therethrough. Opening 126 isformed to allow conductive body 112 to be positioned therein with an end128 of conductive body 112 positioned relatively flush with an end 130of first collar 80. A key 132 is formed between a front section 134 anda rear section 136 of first collar 80. A ledge 138 is formed proximate asecond end 140 of first collar 80 about rear section 136. A second0-ring 142 is positioned about ledge 138 of first collar 80. An opening144 is formed through second collar 82 and is constructed to allow boss84 to engage key 132 of first collar 80 thereby fixing the position ofsecond collar 82 relative to first collar 80. When fully assembled,threaded portion 90 of conductive body 112 extends past an end 146 ofsecond collar 82 and is engaged by nut 88 with washer 92 positionedbetween nut 88 and end 146 of second collar 82.

As shown in FIG. 5, planar surfaces 76 truncate both the shank portion58 and threaded portion 60 of weld cable connector 44. Additionally,planar surfaces 76 are skewed from parallel with a longitudinal plane ofsymmetry 148 such that threaded portion 60 is divided into a firstthreaded section 150 and a second threaded section 152. The skewing ofplanar surfaces 76 provides first threaded section 150 with acircumferential distance that is greater than a circumferential distanceof second threaded section 152. First section 68 of groove 66 of shankportion 58 of weld cable connector 44 is generally aligned withlongitudinal plane 148 and first threaded section 150.

Referring to FIGS. 5 and 6, upon insertion of stem 56 of connector 44into recess 98 of receptacle 42, pin 110 slidingly engages groove 66 ofweld cable connector 44. First threaded section 150 and second threadedsection 152 pass through channels 109 of receptacle 42. Referring toFIG. 6, pin 110 is centered about a longitudinal plane 154 of receptacle42. First threaded section 150 and second threaded section 152 areallowed to pass axially into recess 98 without interference of firstthreaded section 150 and second threaded section 152 with threadedportions 108 of receptacle 42.

FIG. 7 shows connector 44 inserted into receptacle 42. Pin 110, shown inphantom, engages first portion 68 of groove 66 while threaded portion 60of connector 44 passes freely through threaded portion 108 of receptacle42. At this point there is no interference between threaded portion 60of connector 44 and threaded portion 108 of receptacle 42. Additionallya gap 156 is formed between planar surfaces 76 and second section 102 ofrecess 98.

Referring to FIG. 8, upon rotation of connector 44 relative toreceptacle 42, pin 110 travels through second section 70 of groove 66and threaded portion 60 of stem portion 56 of connector 44 engagesthreaded portion 108 of receptacle 42. The pin and groove engagementbetween receptacle 42 and shank portion 58 of connector 44 forms a firstattaching means and the threaded engagement between threaded portions 60of stem portion 56 of weld cable connector 44 and threaded portion 108of receptacle 42 forms a second attaching means of the connectorassembly. Furthermore, the threaded engagement between the threadedportions of the receptacle and the connector forms a contacting surfacearea that is greater than any contact area of the pin and grooveengagement.

FIG. 9 shows the relation of threaded portion 60 of stem portion 56 ofconnector 44 relative to threaded portion 108 of recess 98 uponinsertion of stem portion 56 into recess 98. Channels 109 of receptacle42 receive threaded portions 60 of connector 44 therein. Still referringto the inserted position, as shown in FIG. 10, pin 110 engages groove 66of connector 44. Shank portion 58 of connector 44 is received withinsecond section 102 of receptacle 42. FIGS. 11 and 12 show the engagementbetween connector 44 and receptacle 42 upon rotation of connector 44relative to receptacle 42. As shown in FIG. 11, upon rotation ofconnector 44 relative to receptacle 42, threaded portions 60 ofconnector 44 threadingly engage threaded portions 108 of receptacle 42.

Referring to FIG. 12, pin 110 travels through circumferential secondsection 70 of groove 66 while maintaining electrical connectivitybetween shank portion 58 of connector 44 and second portion 102 ofreceptacle 42. As shown, approximately 90 degrees of rotation ofconnector 44 relative to receptacle 42 forms a quick connect electricalconnector assembly that can quickly and efficiently be connected anddisconnected. Upon rotation of connector 44 relative to receptacle 42,both the threaded portions 60, 108 of connector 44 and receptacle 42and, as shown in FIG. 8, lip 78 of connector 44 and end 111 ofreceptacle 42, are brought into clamping engagement. The clampingengagement distributes the mechanical, electrical, and thermal loads ofthe connector assembly through the multiple thread and component faceengagements of the connector assembly thereby providing increased powertransmitting capability of the connector assembly. Additionally,engagement of pin 110 in groove 66 prevents rotation of plug 44 relativeto receptacle 42 until stem 56 is fully engaged in recess 98 therebypreventing premature rotation of connector 44 relative to receptacle 42.Although shown as having a quarter-turn engagement, it is understoodthat the quick connector assembly preferably has an insertion toengagement rotation of less than approximately 180 degrees.Additionally, by constructing the connector and the receptacle of theconnector assembly of a material having conductivity characteristicssimilar to copper and machineability characteristics similar to brass,such as a tellurium copper alloy or a sulfur copper alloy material, arelatively compact connector assembly can be formed that is capable ofcommunicating approximately 700 amps through the connection with lessthan approximately 40 degrees of temperature change.

Preferably, the individual connectors of the quick-connect connectorassembly are constructed from a material having electrical conductivitycharacteristics of approximately 80% to 85% of that of copper andmachineability characteristics of 70% to 85% of that of free-cuttingbrass, wherein free-cutting brass has a conductivity of approximately26% of that of copper. Additionally, due to the repeated use and therugged operating conditions associated with welding-type devices, theconnectors of the quick-connect connector assembly are constructed of amaterial having a yield strength of at least 40,000 pounds per squareinch. Such a connector has an extended service life and is capable ofrepeated connection/disconnection with relatively minimal wear betweenthe engaging surfaces of the connectors of the assembly. Such aconstruction forms a relatively compact connector assembly capable oftransmitting high power levels required for certain weldingapplications. Additionally, it is further understood that constructingthe connector assembly from a material other than those examplesprovided above, such as from a chromium copper alloy, is within thescope of the claims.

An alternate embodiment of connector assembly 48 is shown in FIGS.13-17. As shown in FIG. 6, a connector assembly 170 includes a cableconnector 172, a first connector, and a receptacle connector 174, asecond connector. Receptacle connector 174 has a first collar 176 and asecond collar 178 positioned about a body 180 of receptacle connector174. A nut 182 and a washer 184 engage and are positioned about an outerthreaded surface 186 of body 180 and secure receptacle connector 174 toa housing (not shown) generally positionable between first collar 176and second collar 178. A boss 188 orients first collar 176 to secondcollar 178 and receptacle connector 174 to the housing. A passage 190 isformed through body 180 of receptacle connector 174 and includes a firstsection 192 having a pair of channels 194 interrupting a threadedportion 196 formed therein. A second section 198 forms a generallyannular groove in passage 190 of body 180 and is disposed generallybetween first section 192 and a third section 200 of passage 190.

Cable connector 172 includes a collar portion 202 and a stem portion204. A plurality of threaded recesses 206 are formed in collar portion202 and constructed to receive a set screw (not shown) therein forsecuring a weld cable to cable connector 172. Stem portion 204 of cableconnector 172 includes a threaded section 208 between collar portion 202and a shank section 210. Shank section 210 is formed proximate an end212 of cable connector 172. A pair of shoulders 214 are formed aboutshank section 210 and truncated by a pair of planar surfaces 216 locatedon generally opposite sides of stem portion 204. During connection ofcable connector 172 to receptacle connector 174, shoulders 214 areconstructed to pass through channels 194 of first section 192 ofreceptacle connector 174. Shoulders 214 are constructed to be receivedwithin second section 198 of body 180 of receptacle connector 174. Uponrotation between cable connector 172 and receptacle connector 174,shoulder 214 rotates within second section 198 of receptacle connector174 and a plurality of threads 218 of threaded section 208 of cableconnector 172 threadingly engage threaded portion 196 of receptacleconnector 174. Such a construction securely connects cable connector 172and receptacle connector 174 with relatively minimal rotationtherebetween.

An end view of cable connector 172 is shown in FIG. 14. As shown in FIG.14, shoulders 214 extend beyond threaded section 208 (shown in phantom)of stem portion 204, the importance of which will be described withrespect to FIG. 17. An end view of receptacle connector 174 is shown inFIG. 15. As shown in FIG. 15, channels 194 interrupt threaded portions196 of receptacle connector 174. The second section 198 (shown inphantom) has a diameter that is somewhat larger than an inner diameterof threaded portion 196. As shown in FIG. 16, stem portion 204 of cableconnector 172 is constructed to be received within first section 192 andsecond section 198 of receptacle connector 174. Shoulders 214 passbeyond threaded portion 196 of receptacle connector 174 withoutinterference therewith. Additionally, when just inserted into receptacleconnector 174, plurality of threads 218 of threaded section 208 do notinterfere with the plurality of threads of threaded portion 196.

Upon rotation of cable connector 172 relative to receptacle connector174, as shown in FIG. 17, plurality of threads 218 of threaded section208 of cable connector 172 threadingly engage the threads of threadedportion 196 of receptacle connector 174. Additionally, shoulders 214rotate freely relative to second portion 198 of receptacle connector 174and prevent the premature rotation of cable connector 172 relative toreceptacle connector 174. The engagement between the threads of threadedsections 208 of cable connector 172 and threaded portion 196 ofreceptacle connector 174 form a clamping engagement both therebetweenand between an end face 220 of cable connector 172 and an end face 222of receptacle connector 174. The clamping engagement of the connectorassembly provides multiple power conducting surfaces within the threadsas well as a power conducting surface at the end faces of the cableconnector and the receptacle connector.

Regardless of which of the above embodiments is employed, although eachembodiment is shown as having a quarter-turn engagement, it isunderstood that each quick connector assembly preferably has aninsertion to engagement rotation of less than approximately 180 degrees.Additionally, by constructing the connector and the receptacle of theconnector assembly of a tellurium copper material, the connectorassembly is capable of communicating approximately 700 amps through theconnection with less than approximately 40 degrees of temperaturechange. Such a construction forms a connector assembly capable oftransmitting high power levels required for certain weldingapplications.

Therefore, present invention includes a high-power quick connectorassembly having a first connector and a second connector. The firstconnector has a collar portion connectable to a welding cable and a stemportion having a shank end and a threaded end. The second connector hasa recess formed therein constructed to receive the stem portion of thefirst connector. The recess is constructed to engage the shank end andthe threaded end of the first connector.

In another embodiment of the present invention, a quick connectorassembly for a welding-type device has a cable adapter having a cableend connectable to a welding cable and a welding device end. A deviceadapter is constructed to engage the welding device end of the cableadapter and has a body having a first end and a second end. A recessextends into the body from the first end and has a threaded sectionformed in the recess proximate the first end. A smooth section is formedin the recess between the threaded section and the second end.

An alternate embodiment of present invention includes a high-power quickconnector assembly having a receiver and a plug. The receiver isconfigured to be connected to a welding-type device and has a firstinner diameter and a second inner diameter wherein the second innerdiameter is greater than the first inner diameter. The plug isconstructed to be connected to a weld cable and has a stud. The stud hasa first outer diameter substantially similar to the first inner diameterof the receiver and a second outer diameter substantially similar to thesecond inner diameter of receiver. A plurality of threads is formedabout the second outer diameter of the stud.

A further embodiment of the present invention includes a method offorming a high-power electrical connection. The method includesproviding a receptacle having a first connection portion and a secondconnection portion and providing a plug having a first engagementportion constructed to electrically communicate with the firstconnection portion of the receptacle and a second engagement portionconstructed to electrically communicate with the second connectionportion upon rotation therebetween wherein a surface area of the firstengagement portion is less than a surface area of the second engagementportion.

Another embodiment of the present invention includes a method ofmanufacturing a high-power quick connector assembly. The method includesforming a receiver having a first internal profile and a second internalprofile and forming a plug having a first external profile constructedto pass the second internal profile of the receiver and engage the firstinternal profile of the receiver, and a second external profileconstructed to engage the second internal profile of the receiver uponrotation therebetween.

An additional embodiment of the present invention includes a high-powerquick connector assembly for welding-type apparatus having means forreceiving a weld cable and means for connecting the receiving means to apower source. The connecting means includes first attaching means havinga contact surface area and second attaching means having a contactsurface area that is greater than the contact surface area of the firstattaching means.

Another embodiment of the present invention has a connector assemblyhaving a cable connector and an output connector. The cable connector isconnectable to a weld cable and the output connector is electricallyconnectable to a power source configured to generate a power signalsuitable for welding applications. At least one of the cable connectorand the output connector are constructed from a tellurium coppermaterial.

The present invention has been described in terms of the preferredembodiment, and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. A high-power quick connector assembly comprising: a first connectorhaving a stem portion and a collar portion connectable to a weldingcable, the stem portion having a shank end and a threaded end; a secondconnector having a recess formed therein, the recess constructed toreceive the stem portion of the first connector and engage the shank endand the threaded end; and wherein the stem portion of the firstconnector further comprises a channel formed therein.
 2. The high-powerquick connector assembly of claim 1 wherein the second connector furthercomprises a pin extending into the recess of the second connector andconstructed to engage the channel formed in the stem portion of thefirst connector.
 3. The high-power quick connector assembly of claim 1wherein the channel extends in a first direction generally axially alongthe stem portion and in a second direction generally circumferentiallyabout the stem portion of the first connector.
 4. A quick connectorassembly for a welding-type device comprising: a cable adapterconnectable to a welding cable and having a cable end and a weldingdevice end; and a device adapter constructed to engage the weldingdevice end of the cable adapter, the device adapter comprising: a bodyhaving a first end, a second end, and an annular groove formed on anexterior surface of the body of the device adapter between the first andsecond ends; a recess extending into the body from the first end; athreaded section formed in the recess proximate the first end; and asmooth section formed in the recess between the threaded section and thesecond end.
 5. The quick connector assembly of claim 4 furthercomprising a pin extending into the recess of the device adaptergenerally between the threaded section and the smooth section.
 6. Thequick connector assembly of claim 4 wherein welding device end of thecable adapter further comprises an unthreaded portion having a grooveextending from an end of the cable adapter to a threaded portion of thecable adapter.
 7. The quick connector assembly of claim 4 wherein thecable adapter further comprises a groove formed in the unthreadedportion, the groove having an axial section extending generally axiallyalong the unthreaded portion and a circumferential section extendinggenerally circumferentially about the unthreaded portion.
 8. The quickconnector assembly of claim 7 wherein the circumferential section of thegroove is positioned between the unthreaded portion and the threadedportion.
 9. A method of manufacturing a high-power quick connectorassembly comprising: forming a receiver having a first internal profileand a second internal profile; and forming a plug having a firstexternal profile constructed to pass the second internal profile of thereceiver and engage the first internal profile of the receiver, and asecond external profile constructed to engage the second internalprofile of the receiver upon rotation therebetween.
 10. The method ofclaim 9 further comprising providing at least one of a tellurium coppermaterial, a sulfur copper material, and a chromium copper material forforming at least one of the receiver and plug.
 11. The method of claim 9further comprising forming a plurality of threads about the secondinternal profile of the receiver and the second external profile of theplug.
 12. The method of claim 11 further comprising forming a grooveacross the plurality of threads of the receiver.
 13. The method of claim9 further comprising forming an annular groove about an outer surface ofthe receiver.
 14. The method of claim 9 further comprising forming arecess in the plug for receiving a weld cable at an end generallyopposite the first external profile.
 15. The method of claim 14 furthercomprising forming a plurality of threaded openings through the pluginto the recess.
 16. The method of claim 9 further comprising forming aplurality of threads about an internal surface and forming a pluralityof threads about an external surface of the receiver about an endgenerally opposite the second internal profile.
 17. The method of claim9 further comprising attaching the receiver to a power source capable ofgenerating a power signal suitable for welding.
 18. The method of claim9 further comprising forming a rib extending from the first externalprofile of the plug.
 19. The method of claim 18 wherein a majority ofthe second internal profile of the receiver has a diameter that is lessthan a diameter of the rib extending from the first external profile ofthe plug.
 20. The method of claim 9 further comprising forming a groovein the first external profile of the plug.
 21. The method of claim 9further comprising positioning a pin in the receiver generally betweenthe first internal profile and the second internal profile.
 22. Themethod of claim 9 further comprising locking the plug to the receiver inless than 100 degrees of rotation between the plug and the receiver. 23.A connector assembly comprising: a cable connector connectable to a weldcable; an output connector electrically connectable to a power sourceconfigured to generate a power signal suitable for welding applications,the output connector including a locking pin constructed to engage alocking groove formed in the cable connector; and wherein at least oneof the cable connector and output connector are constructed from atleast one of a tellurium copper material, a sulfur copper material, anda chromium copper material.
 24. The connector assembly of claim 23wherein the locking groove includes a first portion that extends axiallyalong the cable connector and a second portion that extendscircumferentially about the cable connector.
 25. The connector assemblyof claim 23 wherein the cable connector further comprises a threadedsection having an outer diameter that is greater than a diameter of aportion of the cable connector having the groove formed therein.